Screening methods and apparatus

ABSTRACT

An apparatus ( 25 ) for use in screening a liquid and solids mixture feed ( 2 ) comprises a conduit ( 18 ), including a screening portion ( 22 ) that is formed and arranged to divide a liquid and solids mixture feed flowing through the conduit. The feed ( 2 ) is divided into a first, cleaned stream (C 1 ) comprising liquid and solid particles of below a selected size limit, and a second, concentrated, stream ( 24 ) comprising liquid, and particles above the selected size limit. The apparatus ( 25 ) may be a stand alone module, part of a system with other solids and liquids separating equipment or an integral part of a solids and liquid separator such as a shale shaker. Methods of using the apparatus ( 25 ) are also described.

FIELD OF THE INVENTION

The invention relates to methods used for the separation of drilled solids generated during the process of drilling an oil well, from drilling mud. It is also applicable in wider applications such as mineral processing, dewatering, processing of waste fluid streams, quarrying, pharmaceuticals and food processing. Apparatus for use in the methods is also provided.

BACKGROUND TO THE INVENTION

Screening is used to separate solids according to particle size and or to separate solids from fluids. The solids to be screened may be dry or wet and may often be screened from a flowable solids and liquids mixture (slurry). The process is used in many industries including: mineral and metallurgical processing, quarrying, pharmaceuticals, food and the drilling of oil, water and gas wells. The design of screening equipment varies widely but will generally be of one of two types, either static or moving.

Static screens generally include coarse screens and sieve bends. These are normally mounted at an angle such that solids on the screen roll over it by gravity and in so doing either pass through the screen or roll off it. Static screens are typically used to screen down to 5 mm. Sieve bends may be used to screen finer sizes.

Moving screens are generally described according to the motion of the screen. Types will typically include: revolving rotary screens, shaking screens, gyratory screens, linear screens and high frequency vibratory screens. Moving screen arrangements normally have two elements, the screen panel and the screening machine.

Screen panels will generally be mounted in the screening machine in such a manner that they may be removed and replaced either when worn or damaged or when a change in separation size is required. Screen panels may be constructed of widely differing materials, including but not limited to, woven wire mesh, wedge wire, moulded plastics, synthetic woven fabrics and drilled plates of either plastic or metal. Screen panels are made with different hole sizes to provide separation at different sizes.

The function of the screen panel is:

-   -   To retain solids above screen aperture size on the panel.     -   To transmit the motion generated within the screening machine to         the solids and liquid, such that the fluid passes through the         screen and the solids retained on the screen are transported on         the screen to a point of discharge from the screen.     -   To allow fluid and solids under screen aperture size to pass         through the screen.     -   To ideally offer resistance to blinding and plugging of the         screen apertures from solids that are of similar size to the         screen aperture size.

The screening machine design will vary widely according to the movement that it is required to impart to the screen panel, the number of screen panels, the method of feeding the panels, the process application, working environment and process capacity required. The screening machine motion will normally be arranged to impart energy to the screen panel such that:

-   -   Solids under screen aperture size are moved in such a manner         that encourages them to pass through the screen. These solids         are termed ‘undersize’     -   Solids that are larger than the screen aperture and as such         cannot pass through the screen are retained by the screen and         transported off the screen. These solids are generally termed         ‘oversize’. Any fluid discharged from the screen with the         oversize solids is generally termed ‘screen overflow’.     -   Fluids carrying solids are encouraged to pass through the         screen. Fluid passing through the screen is generally termed         ‘screen underflow’.

Moving screens are used for the screening of either dry or wet solids and or the screening of solids from fluids. Dry screening will typically be used for separation of dry solids down to 1 mm diameter. For sizes lower than 1 mm, wet screening will normally be used. This method eliminates dust. Wet screening will normally be the screening of solids from a flowable slurry, being a mixture of solids and a fluid (liquid).

Where a slurry is screened to remove the majority of the fluid from the solids, without any specific need to size the solids, the function of the screen is generally termed ‘dewatering’. This term is applied to the function of the machine and will apply to slurries that are made with water or any other liquid as the fluid.

Where slurry is screened to achieve a specific size split the function of the screen is termed ‘classification’.

In addition to screening equipment making use of screen panels as described above, other types of solids/liquids separators can be used, for example centrifuges such as decanting centrifuges, to separate a solids/liquids mixture.

Whilst screening machines, especially vibratory screening machines such as the so called ‘shale shakers’ of the oil well drilling industry are used with success in methods of solids/liquids separation, especially classification, there is a need to improve throughput and effectiveness. This is especially the case where available space is severely limited, for example on offshore oil rigs, and the option of increasing equipment size or the numbers of machines employed may not be available.

During the drilling of an oil well, fluid known as mud is circulated, under pressure, inside the drilling assembly to the drill bit. One of the functions of the drilling mud is to carry the rock cuttings generated during the drilling process at the drill bit, out of the borehole.

The constitution of drilling mud varies according to the mud type. Generally the mud will contain a fluid phase and a solids phase. The solids phase may include a weighting agent such as Barite that is added to the fluid to control the density of the mud. Other weighting agents can be employed. Generally weighting agents are made of materials that are of high specific gravity, typically within the range of 3.2 to 4.4 SG. The weighting agent will normally be an inert material that will have minimum impact on the viscosity and fluid properties of the drilling fluid when added in various concentrations. The size of the weighting agent particles will normally be below 74 microns with the majority of the particles being under 40 microns diameter. As the weighting agent is added to the drilling mud to control the density of the drilling mud during use, it is generally desirable that the weighting agent is not removed from the mud system but retained within it. Other desirable solids can be incorporated into the mud system such as ‘Bridging’ and ‘Lost Circulation Material’. These solids will generally be of within a desirable size range such that they perform the function for which they are designed.

When the drilling mud arrives at the drilling rig the solids fraction of the mud will contain desirable solids and drilled solids. The drilled solids are generally undesirable solids comprised predominantly of rock but can contain metal fragments. The drilled solids are undesirable as these are generally rock cuttings that if allowed to accumulate at increased concentrations result in undesirable effects on the fluid properties of the mud. As the concentrations of drilled solids in a mud increases the fluid properties are affected until the mud becomes unusable and requires replacement or the addition of new mud to dilute the concentration of drilled solids such that the desired fluid properties are restored. The removal and control of the concentrations of drilled solids is generally regarded as a most important activity in contributing to the successful, safe and economic drilling of an oil well, within the planned time and cost.

The process of removal of drilled solids must remove drilled solids while leaving desirable solids such as weighting material within the fluid. Drilled solids are conventionally removed from the mud using first shale shakers to screen the fluid. Rock cuttings above screen size are removed during screening and the fluid passes into storage tanks for subsequent mechanical and chemical processing, where this is desirable, and ultimate recirculation to the oil well. After screening at the shale shaker additional solids separation techniques can be applied to remove any drilled solids that have passed through the shale shaker, being smaller than the screen size fitted to the shale shaker.

These techniques conventionally include the use of hydrocyclones of various sizes and centrifuges. A large diameter hydrocyclone is conventionally termed a Desander and smaller diameter hydrocyclones is conventionally termed a Desilter. The terms Sand and Silt used in the context above are geological terms referring to the size of the particle concerned. Sand in generally above 74 microns diameter and silt can range down to a few microns in diameter. Centrifuges can be of varying types and configuration, decanting centrifuges are typically employed to separate fine drilled solids. A combination of decanting centrifuges can be used to recover weighting agents and remove drilled solids.

Solids control equipment typically removes solids within the following size ranges:

Conventional Shale shakers Solids above 74 microns. High efficiency Shale Shakers Solids above 40 microns. Desanders Solids between 1000 and 74 microns. Desilters Solids between 74 and 10 microns. Decanting centrifuges Solids between 200 and 5 microns.

When choosing the type of equipment to be employed to remove and control the concentration of drilled solid in the mud the following are generally accepted desirable criteria:

The process should be as simple as possible.

Drilled solids should be removed at the earliest possible opportunity when they are at their largest size.

Pumping, recirculation to the oil well and aggressive handling that results in the fracture of the drilled solid into smaller particles must be avoided, as small solids are significantly more difficult to remove from the mud than large solids.

Drilled solids should not be allowed to be recirculated to the oil well as during recirculation they will be broken down and become increasingly difficult to remove.

The minimum equipment necessary to achieve the function should be employed.

Equipment should be easy to operate for the operators thereof.

The installed system should ideally be of low weight, size and power consumption.

The system should offer high efficiency of separation.

The system should be reliable.

The efficiency of drilled solids removal should be easily measured.

Desanders, desilters and centrifuges suffer from the following undesirable features:

-   -   A feed tank containing feed mud is required this is generally         large and heavy,     -   A feed pump is required resulting in high power requirements,         maintenance, weight and space.     -   During pumping of the drilled solid it is normally fractured and         reduced in size making it significantly more difficult to remove         from the mud.     -   Basis of separation is by the mass of the cutting not size.         Desirable solids such as weighting material are of high specific         gravity. Drilled solids are generally of lower specific gravity         material within the range of 2.8-2.2 sg. The mass of a weighting         agent particle can be similar to the mass of a much larger         drilled solid, resulting in the hydrocyclone separating both         desirable weighting material and undesirable drilled solids of         similar mass. It will be noted that this problem does not occur         with screening as the screen separates by size.     -   Separation efficiency is variable as fluid properties vary.     -   Separation efficiency is difficult to measure.     -   Decanting centrifuges capital cost and maintenance cost are         high.

Shale shakers are conventionally employed in preference to other equipment due to the following characteristics

-   -   No feed tank required.     -   Equipment is simple for the operator to understand and easy to         operate and maintain.     -   Installed space and weight and typically low.     -   Power consumption is low.     -   Basis of separation is size.     -   Separation efficiency is easily determined being directly         relative to the mesh size fitted.     -   Separation efficiency is not variable with fluid properties         provided the fluid passes through the mesh size fitted.

The drilling mud returning to the drilling rig from a well normally contains a low concentration of drilled solids within a large volume of fluid. The drilled solids removal system is thus required to process a large volume of fluid to remove a small volume of drilled solids. Consequently the size of a drilled solids removal system has historically been directly relative to the volume of fluid to be processed and NOT the volume of solids to be removed.

The oil industry has previous employed hydrocyclone and screen (e.g. in shale shakers) combinations to concentrate the volume of solids into a smaller volume of fluid. One such typical apparatus is called a mud cleaner. Mud cleaners typically employ hydrocyclone assemblies mounted above a shale shaker or shakers. Mud is pumped to the hydrocyclone, where the mud is split into two streams, the hydrocyclone overflow, comprising cleaned fluid and the hydrocyclone underflow containing fluid and drilled solids that is passed to the shaker for removal of oversize solids. Analysis of the performance of the mud cleaner has demonstrated that low solids removal efficiencies resulted due to the following:

-   -   Drilled solids were fractured into smaller particles during         pumping to the hydrocyclone resulting in them becoming         increasingly difficult to separate.     -   Separation efficiency was highly variable, dependant on mud         fluid properties.     -   The hydrocyclone was easily overloaded with solids. When         overloaded drilled solids were returned to the mud system in the         cone overflow thus bypassing the separation system.     -   Monitoring the separation efficiency of the hydrocyclone was         difficult and complex.

The analysis also demonstrated that the efficiency of separation achieved by the fine screen element of the mud cleaner was consistently high, determinable and easy to monitor in the field. Historically this analysis led the industry away from hydrocyclone/screen combinations and towards the development of higher capacity shale shakers such as the AX1 Shale Shaker manufactured by Axiom Process Limited.

One or more shale shakers are used depending upon the volume of fluid being pumped and the separation efficiency required. Generally as finer screens are fitted to the shale shaker the process capacity of the shaker decreases while the efficiency of separation of solids increases. Typically screening will take place using screens, generally made of woven wire mesh, of between 10 and 400 mesh. These screens will contain between 10 and 400 wires per inch respectively and aperture hole size will vary according to the weave pattern and diameter of the wire used in the weave.

To achieve the required process capacity and separation efficiency a drilling rig shale shaker installation will typically contain between one and eight shale shakers although some installations can employ more machines. Machines will be employed to work in parallel where the fluid from the oil well is split into multiple streams and processed by an equal number of machines. Installations of shale shakers can thus be appreciable in size.

Alternatively an installation can contain multiple machines working sequentially (in series), each separating at a progressively finer size. Alternatively an installation can contain a combination of machines working in parallel and series.

The need to design a vibratory screening machine to provide the required fluid throughput while transporting solids to the point of discharge from the screen has resulted in conventional machines being of a larger size or in greater numbers than is ideal where space and weight are restricted by either physical or economic factors.

An object of the current invention is to provide methods and apparatus that can significantly increase the processing capacity of a screening system allowing the size of the system to be significantly reduced, relative to a conventional approach, for a given process capacity.

The invention herein relates to a method and equipment for improving the volumetric capacity of wet screening equipment. Typically the equipment will be used for performing a classification function and typically the solids particle size range will be of the order of between 10 mm and 10 microns. However the methods and apparatus may be used for other solids/liquids separations, with particle sizes out with that range.

DESCRIPTION OF THE INVENTION

According to a first aspect the present invention provides a method of screening a liquid and solids mixture feed, suitable for use in recycling drilling mud, the method comprising:

-   -   dividing the feed, by screening, into a first, cleaned stream         comprising liquid and solids of below a selected particle size         and a second, concentrated, stream comprising liquid and solids         above a selected particle size; and     -   directing the second stream to an apparatus for further         processing.

The further processing may include separating at least some of the solids from the liquid in the second stream.

The apparatus for further processing may be a screening apparatus such as a vibratory screening machine (e.g. a shale shaker) for example. The shale shaker may separate solids of a selected size from the second stream. Alternatively the second stream may be further divided, for example by a hydrocyclone into further streams with different loads of solids in each. Other options are discussed hereafter.

The division of the feed into the two streams may be accomplished by use of a suitable screen for example a screen of a woven wire mesh, wedge wire, moulded plastics, synthetic woven fabrics or drilled plates of either plastic or metal. The apertures in screening plates may be produced by laser or chemical etching processes or some other suitable method. The screen may be mounted in a suitable screening machine. Both of the two streams are flowable; the first stream can flow or be pumped to a holding tank, or to a further processing step or be recycled directly and reused. The second stream can flow or be pumped to the screening or other solids liquid separation apparatus. The second stream is concentrated in the sense that the amount of solid particles above the selected size has been increased relative to the liquid volume. The first stream removes liquid (and undersize solids) from the stream that is then further processed in the screening or other solids liquid separation apparatus.

The feed may be subject to a pre-treatment before being divided, for example it may be passed through a screen, typically a coarse mesh screen (a “scalping screen”) to remove large particles.

Screening apparatus employed to process the second stream may be of any suitable type for the solids/liquid separation intended, for example a centrifuge, such as a decanting centrifuge or a vibratory screening machine (a shale shaker). A combination of different screening apparatus may be employed, for example high efficiency shale shakers followed by centrifuges. In this context the processing of the second stream may include any chosen method or combination of methods of processing that may alter the solids content (in terms of concentration of solids or classification by particle size or particle density). Thus the processing methods may include use of apparatus such as hydrocyclones to further divide the second stream. For example the second stream may be divided into e.g. a third stream containing higher mass particles and a fourth stream containing lower mass particles.

The design of the High Capacity Shale Shaker mentioned above in the Background to the Invention is limited by the need to separate fluid and solids while providing a mechanism for the solids to be discharged from the shale shaker screen. In the application of the current invention separation is achieved in stages. The first stage does not require separation of solids from liquid as it uses screening to separate the fluid into two streams, the first stream being the majority of the fluid volume and solids under screen size, and the second stream being the minority of the fluid volume within which is concentrated the majority of solids above screen size. After processing by the invention the first fluid stream is typically directed to a storage system, (for example the mud storage system when dealing with used drilling mud) for recirculation and the second fluid stream is directed to high efficiency shale shakers, or other liquid and solids separation equipment, where fluid and drilled solids are separated.

The advantages of the method of the invention may be summarised as follows:

The use of screening allows all of the advantages of screening separation to be used eliminating the disadvantages or hydrocyclone and centrifuges.

Separation efficiency is easily determined on site, without complex analysis as it is based on size not mass.

The equipment is simple to build, operate, monitor and understand.

The elimination of the need to separate solids and liquids in the first stage allows screening techniques to be employed in the invention that result in previously unobtainable fluid throughputs from any given screen (typically a mesh) area resulting in a significant reduction in machine size.

The size, weight, power requirement and cost of the downstream shale shaker installation (or other screening system, processing equipment or combination of processing equipment) can be reduced.

The process is simple and easy to understand, monitor and operate.

As the process capacity of the invention is significantly higher than conventional screens and the load on downstream shale shakers is reduced the efficiency of solids removal can be increased by the use of finer screens.

Conveniently the division of the feed into the two streams is carried out as the feed flows along a conduit fitted with a screening portion.

Thus according to a second aspect the present invention provides a method of screening a liquid and solids mixture feed, the method comprising:

-   -   providing a conduit, including a screening portion and formed         and arranged to divide the feed flowing through the conduit into         a first, cleaned stream comprising liquid and solid particles,         of below a selected size, and a second, concentrated, stream         comprising liquid and particles above the selected size; and     -   passing a liquid and solids mixture feed through the conduit.

The method may include directing the second, concentrated stream to a screening apparatus (or more than one of the same or different types) for subsequent treatment where solids are separated from the liquid of the second stream (or are otherwise further processed using suitable equipment) as described in respect of the first aspect of the invention. However if a solids/liquid separation is not required the conduit may be used simply to concentrate a liquid and solids feed. As a yet further alternative the solids and liquids mixture feed may already have been processed before it is passed through the conduit. For example larger particles may have been removed by a scalping screen or the feed may have been processed through one or more of a vibratory screening machine (e.g. a shale shaker), centrifuges, hydrocyclones such as desanders, desilters or the like.

A significant advantage provided by the method is that a screening operation is carried out without a requirement for solids handling. The screening operation using the conduit produces two fluid (i.e. flowable) streams of a liquid and solids mixture, by appropriate choice of equipment for a given task.

Avoiding concentrating the oversize solids to the point where they are a solid or semi-solid mass has notable advantages.

The flowable streams can be readily conveyed (e.g. along a pipe by pumping and/or gravity) to their destination for further processing, storage or use. Handling isolated solids, (especially isolated wet solids that are often cohesive i.e. sticky) as occurs with other screening methods requires more complex equipment. By making use of the method of the invention a substantive screening process can be carried out producing two flowable streams. Even if one or even both of the streams produced is to be subject to a further processing including a solids isolating step, the work required on a given stream is reduced in terms of volume of fluid and/or amount of solids to be handled.

It will be appreciated that either of the two streams produced may be of higher value or greater use than the other, depending on the application and the reason for the screening process being carried out. Thus the term ‘cleaned’ when referring to the first stream as used herein simply denotes the removal of larger sized particles, by the use of the screening portion of the conduit, from the original feed.

Thus the present invention provides an apparatus for use in screening a liquid and solids mixture feed, the apparatus comprising:

-   -   a conduit, including a screening portion and formed and arranged         to divide a liquid and solids mixture feed flowing through the         conduit into a first, cleaned stream comprising liquid and solid         particles of below a selected size limit, and a second,         concentrated, stream comprising liquid, and particles above the         selected size limit.

The apparatus may be used in the methods according to the first or second aspects of the invention. The liquid and solids mixture feed may be a drilling mud composition, in particular a used drilling mud composition comprising drill cuttings.

The conduit may be formed and arranged to direct the second, concentrated stream to a screening apparatus, or other processing equipment, for subsequent treatment.

Advantages of the apparatus include:

The apparatus may be used as a stand alone module or as an integral part of a screening machine; and

The apparatus can be used in combination with existing shaker installations allowing upgrade of existing installations at low cost.

The apparatus may be used ahead of equipment other than shale shakers, such as centrifuges, for example decanting centrifuges. In this application the apparatus will reduce the fluid load on such equipment allowing performance to be improved and or less equipment used.

As an alternative the apparatus may be used after conventional equipment. For example to provide fine screening of a used drilling mud after drill cuttings and larger particles have been removed by shale shakers and/or other processing equipment.

Typically when used ahead of other separating equipment the subsequent processing will involve separating solids from the second stream solids and liquid mixture, for example by use of a vibratory screening machine, a centrifuge or other solids/liquid separations device. The methods described herein have the advantage of reducing the volume of mixture feed that has to be processed by relatively complex, expensive and often bulky screening equipment. The proportion of solids relative to liquid present in the second stream is increased. Thus the equipment that separates the solids from the liquid may be reduced in size for a given volume of feed to be processed.

Screening by the conduit can therefore reduce the overall footprint of screening apparatus employed, for example in oil drilling operations and/or improve throughput. At the same time as the mixture feed is divided into streams that flow (solids dispersed in a liquid) by the method, there is no requirement for extra solids handling operations. The screening portion operates to “pre-screen” the feed in advance of a solids removal step by the screening or other liquid solids separation apparatus.

Advantageously for some applications the conduit may include two or more screens that may be located in the same screening portion or in different screening portions of the conduit. The screens are formed and arranged to operate in a series fashion with successive screens having finer mesh.

For example where two screens are used the liquid and solids feed is divided by the first screen into a first cleaned stream (passing through the first screen) and a second concentrated stream not passing through the first screen as described above.

The first, cleaned, stream is then processed further by the second screen which will have a finer mesh than the first. This results in a first cleaned stream that has passed successively through both screens and another concentrated stream, of liquid and solids that has passed the coarser first screen but not the finer second screen. The two concentrated streams produced may be recombined for further processing or use or they may be kept separate and directed (e.g. along separate branches of conduit or pipe) for separate further processing storage or use.

Therefore the methods and apparatus described herein may be used for progressive screening operations without necessarily requiring the use of other processing equipment.

Thus the present invention provides a system for screening a liquid and solids mixture feed, the system comprising:

-   -   an apparatus including a conduit, the conduit including a         screening portion formed and arranged to divide a liquid and         solids mixture feed flowing through the conduit into a first,         cleaned stream comprising liquid and solid particles of below a         selected size limit, and a second, concentrated, stream         comprising liquid, and particles above the selected size limit;         and     -   screening or liquid and solids separating apparatus for         processing the second stream.

The screening apparatus for processing the second stream may be a screening machine such as a shale shaker or any other type of vibratory screening device. Alternatively hydrocyclones, centrifuges or any other solids and liquids separator may be employed. A combination of screening apparatus of the same or different types may be used in the system. They may operate in series or parallel or some combination of series and parallel.

In an alternative approach the present invention provides a system wherein the liquids and solids mixture feed is processed in the conduit as discussed above but the second stream is not necessarily further processed. This can occur when the system has screening or liquid and solids separating apparatus provided before the apparatus including the conduit and the conduit carries out a final screening operation.

In the field of drilling operations the methods, apparatus and system of the invention can be operated particularly advantageously. Typical drill cuttings and drilling mud streams generally contain a high proportion of liquid to solid. For example during the drilling of an oil well the mud returning to the surface for processing by a shale shaker (vibratory screening machine) will typically contain between 0.1 and 10% by volume of drilled solids that are of a size capable of separation by a shale shaker. The volume of drilled solids to be separated by the shale shaker will thus normally be a relatively small volume compared to the volume of fluid to be processed.

The throughput of screening apparatus employed, such as vibratory screening machines, tends to be limited by the volume of liquid being processed rather than by the solids content. By dividing the feed into the two streams the screening or other liquid solids separation apparatus can be used more effectively, on a concentrated (second) stream of solids and liquids.

The first, cleaned stream may be directed to a tank or other receptacle for subsequent treatment, recycle, reuse or disposal. Alternatively the first stream may be reused, (e.g. where the feed is a used drilling mud, by returning the cleaned stream into a drilling mud stream) immediately after screening in the conduit screening portion. As a yet further alternative the first stream may be directed to further processing equipment, for example a vibratory screening machine where at least some of the solids content may be removed before reuse, recycle or disposal.

The screening portion of the conduit employed in the apparatus, methods and systems described herein may take several different forms. For example the conduit may be a pipe or channel having a screen mesh or other filter material that replaces part of its wall. Screens may be mounted vertically, horizontally or at any angle or combination of angles between vertical and horizontal. The first, cleaned stream or filtrate (liquid together with solids below the mesh size) will pass through the mesh and can be directed to subsequent treatment as desired. For example, by means of a further section (e.g. a branch) of conduit.

Alternatively the conduit may incorporate a secondary, internal conduit (e.g. a pipe) that has a portion of wall replaced by a screen mesh or other screen or filter material. Liquid and undersized solids from the feed passing along the (outer) conduit, passes through the screen mesh and into the internal conduit and is then directed as required.

Multiple internal conduits may be employed and may be formed in any convenient shape or shapes to provide the desired division into the two streams and overall flow rate. For example cylinders, hexagonal prisms or cuboids as illustrated hereafter with reference to specific embodiments.

Where multiple screens operating in series are used in a conduit screens may be for example, spaced apart from each other and stacked in a section of conduit. Alternatively series screening in the conduit may be obtained e.g. by having two internal conduits, one inside the other and each having a screening portion.

Multiple conduits such as those described herein may be employed in the method. The conduit or conduits may be of any convenient shape.

For efficient operation of the apparatus the screening portion should operate with minimum downtime, in particular it should be arranged to, as far as possible, avoid blinding or clogging of the screen mesh or other filter material during use. This possibility may be avoided to some extent by the flow of the feed along the conduit constantly washing the screen mesh.

Additional clearing action can be achieved by having at least the screening portion of the conduit subject to vibration. For example by locating the conduit in a “basket” that is mounted on resilient mountings such as springs and vibrated in a similar fashion to that of a typical vibratory screening machine. Typically vibration is by means of a pair of electric motors having eccentric (or eccentrically weighted) shafts turning in opposite directions. The vibration tends to keep particles in the feed mobile or fluidised and can provide a clearing effect, removing particles of solid blocking a screen mesh or other screening material while assisting fluid to flow through the screen. The conduit may also be designed such that the fluid passes through it when in turbulent flow e.g. by the provision of baffles, thus further assisting the passage of oversize solids through the conduit.

It will be readily apparent to the skilled person that the design of the apparatus can be adjusted to provide the desired degree of screening to the first stream and concentration to the second stream, for a given expected feed, in a number of ways.

Adjustment of the following factors can be made:

-   -   a) The method of entry of the feed to the screen;     -   b) Employing different methods to avoid settling of solids such         as:         -   pre-screening using e.g. a scalping screen to remove large             particles or a         -   hydrocyclone to remove dense particles;         -   providing baffles to obtain turbulent flow;         -   adjusting the flow rate across the screen face;         -   adjusting the depth of fluid on each side of screen;         -   changing vibration characteristics applied to the conduit;             and         -   changing any one or more of the shape or size of: the             screen, the conduit, and the fluid outlet for concentrated             fluid.

For typical operations fluid flow velocities within the conduit may be in an operational range of about from 5 to 500 feet per minute (about 1.5 to 150 metres per minute).

Thus when provided as a stand alone module the apparatus may comprise the conduit with means to vibrate it. The feed may be supplied to the vibrating conduit by means of a conduit or pipe, that may provide the feed from a source such as a head tank or by a pump from a storage tank The vibrating conduit may be connected to the feed conduit by a portion of flexible pipe or bellows. Similarly the two product streams from the module may be directed onwards for further processing or storage via suitable conduits or piping that may be connected to the vibrating conduit by flexible connections. A stand alone module may also include a scalping screen (that may be vibrated) upstream of the conduit, for removal of large particles that might reduce the effectiveness of the conduit and contribute to reduced conduit screen life.

As an alternative the apparatus may be integrated within further processing equipment, for example may be provided in the basket of a vibratory screening machine, such as a shale shaker. For example the apparatus in a shale shaker basket may provide a first screening to a used drilling mud feed. The cleaned stream may be suitable for reuse directly in drilling mud or may be further processed. The second, concentrated stream is then passed through the screen(s) of the shale shaker to remove the larger sized solid particles and provide further fluid for reuse or further processing. Conveniently the feed may be fed through a scalping screen, to remove large particles before being passed through the conduit. The scalping screen can be provided integral with the basket.

As a yet further alternative the apparatus may be integrated in a basket of a shale shaker or other vibratory screening machine, but may be located after the screens to divide already screened fluid into a cleaned stream and a second, concentrated stream.

Advantageously the screening of the feed effected by the screening portion of the conduit is carried out in an upwardly flowing direction. The fluid that is screened passes upwardly from the conduit through the screen mesh. This approach has the advantage that the screen mesh tends to be kept clear by the action of gravity. Oversize particles held against the screen mesh will tend to fall off, back into the flow of feed towards subsequent screening apparatus. Alternatively filtration through the mesh may be in a downward or lateral direction or in any other suitable direction or combination of directions.

Furthermore where a vibratory action is employed the presence of a layer of screened fluid above the mesh, as described hereafter with reference to a specific embodiment, may be advantageous. The vibrating action can result in a to and fro pumping action in the fluid through from one side of the mesh to the other that assists in keeping both sides of the screen clear of accumulated solids.

Advantageously the screening portion of conduit has a portion of screen mesh or other filter material on an upwards facing portion of wall and the feed is supplied at a slight positive pressure so as to effect upwards filtration through the screen mesh. Even where the screening portion is at any angle supplying the feed at a slight positive pressure so as to encourage its passage through the screen mesh is advantageous.

Conveniently this can be arranged by having a feed conduit with a screening portion that is at a lower height than the inlet end of the conduit, thus producing a pressure (a head pressure) at the screening portion.

Conveniently either the outlet from the conduit may be limited in size, such that a head of fluid creating a positive pressure on the screen is created. Alternatively or additionally the outlet from the conduit may be positioned at a level above the height of the screen such that a head of fluid is created resulting in a positive pressure on the screen. A weir arrangement may be provided as discussed below. In either case the positive pressure on the screen assists flow through the screen.

Fluid throughput is proportional to pressure for a given size of conduit. Typically a head or pressure equivalent to between 50 mm and 2000 mm will be used. The head will be limited by the ability of screening material employed to withstand the load i.e. the operating pressure will be determined by the ability of the screening material to withstand the operating pressure without failing. Where a screening material has the ability to be operated with higher pressure heads above 2000 mm may be used. For example a wedge wire screen will typically be capable of operation at a pressure significantly higher than that of a woven wire screen with a similar aperture size.

In a particularly advantageous arrangement the conduit is mounted in a vibrating basket or is itself mounted on resilient members and is directly vibrated. It has a downwards directed (e.g. vertical) inlet end followed by a generally horizontally disposed screening portion that has a screen mesh replacing a portion, for example an upper portion of conduit wall. The conduit continues by having an upwardly directed (e.g. vertical) outlet end. The end of the outlet end is at a lower height than the inlet and acts as a weir over which the second stream flows and may then be directed to a subsequent screening apparatus. This form of conduit, with an overall ‘U’ (or ‘J’) shape provides a robust, relatively simple in construction apparatus. The mixture feed flows around the U by virtue of the head pressure from the inlet end. The head pressure produced by the raised outlet end acts to force liquid and undersize solids upwards through the screen mesh (where it is on an upper portion of conduit wall) to produce the first cleaned stream, that can then be directed as desired, for example to a tank for recycling. Such an arrangement is shown in an embodiment described in more detail hereafter.

Advantageously the height of the outlet end or a weir associated with the outlet end can be variable. This allows the flow rate along the conduit to be controlled so as to obtain the desired amount of screening in the screening portion whilst at the same time maintaining sufficient flow rate to avoid settling out of solids within the conduit. The height of the outlet may be fixed or varied either manually or automatically. If controlled automatically or manually the head of fluid may be varied to increase or decrease the head in order to achieve the required process flow rate of the screen to process the flow arriving at the inlet.

Alternative arrangements are possible. For example the conduit may have a generally U shape as described above but the screening portion, in the form of a portion of conduit with a mesh panel replacing part of the wall, may be formed on the downwardly directed (inlet) end or on the upwardly directed (outlet) end. In either case the pressure produced by the head will force liquid and undersized solids outwardly through the mesh panels or other filter material employed.

Alternatively the conduit may be L shaped with the inlet end above the screen and the discharge end below the screen. The rate of discharge is controlled by a size of the discharge orifice. The orifice may be fixed size or variable. If variable it may be manually controlled or controlled by an automated control system such that a head of fluid is maintained within the conduit and the resulting pressure assists flow of the fluid through the screen. If controlled automatically or manually the head of fluid may be varied to increase or decrease to achieve the required process flow rate of the screen to process the flow arriving at the inlet.

Alternatively the solids and liquid mixture may be pumped into the conduit at a pressure that is suitable to assist flow through the conduit and the screening action.

The outlet from a conduit supplied by a pump may be over a weir the height of which may be adjustable or fixed. In this arrangement the head of fluid created by the height of the weir assists flow across the screen and thus the rate of processing of the fluid while the rate of pumping controls the velocity of fluid in the conduit. According to this arrangement the fluid velocity can be controlled to ensure that no settling of solids occurs within the conduit and all solids are carried forward to the conduit outlet. Control of the height of the weir may be manually or automatically adjustable. If automatically control is employed a suitable control system may be employed to adjust either the height of the weir, thus controlling the pressure of fluid on the screening portion of the conduit and consequently the process rate through the screen. Alternatively the pumping rate may be adjusted to ensure adequate fluid velocity is maintained within the conduit. Alternatively both the height of the weir and the input rate are controlled to allow optimisation of process rate and velocity for a given feed mixture.

Alternatively the solids and liquid feed may be pumped into the conduit at a pressure suitable to assist flow across the screen and the outlet from the conduit arranged with an orifice of variable or fixed size. The position of the orifice may be either above or below the screen. In this arrangement the pressure within the conduit is maintained at a level suitable to effect flow through the screen by a combination of input rate and the size of outlet orifice. The pump rate and pressure may be fixed or variable either manually or by an automated method. The orifice size may be fixed or variable either manually or by an automated method. Advantageously adjustment of the pump rate, pressure and orifice size may be automated to effect optimum operation of the system. The pressure employed may typically be equivalent to the head pressures discussed above with respect to apparatus including a weir and/or an inlet above the height of the screening portion.

When used for oil well drilling operations the first stream comprising screened cleaned fluid will typically be, but is not limited to, between 20 and 80 percent by volume of the total flow arriving at the shale shaker or other solids/liquids separator, from the oil well. This stream having been processed is directed to the mud storage system where it may be subjected to further processing by equipment such as centrifuges or chemical processing prior to recirculation to the oil well.

The second, concentrated, stream will typically be, but is not limited to, between 20 and 80 percent by volume of the total flow arriving at the shale shaker from the oil well. This stream is passed to, for example, a shale shaker for screening where fluid and drilled solids above screen size are separated. Drilled solids are rejected and processed fluid is directed to the mud storage system where it may be subjected to further processing by equipment such as centrifuges or chemical processing prior to recirculation to the oil well. The volume of fluid to be processed by the shale shaker is significantly reduced and the size of the shale shaker can be reduced proportionately.

The two stage process described herein—first screening the mixture in the conduit and then carrying out a solids liquid separation—allows techniques to obtain high fluid throughput to be adopted in the design of the first stage equipment without the need to separate solids into a separate stream from the fluid. This allows significant flexibility in the design to be adopted. A design can be adopted that allows a large proportion of the fluid arriving from e.g. a well to be processed through a screen of small physical size (the screen on the screening portion of the conduit). The remaining fluid, the second stream, in which the solids above screen size are concentrated, can be processed by a second stage screen or other screening/liquids and solids separation machine such as a centrifuge, that is physically smaller than that previously used for single stage processing.

This two stage approach allows the overall volumetric process capacity of a screening machine to be significantly increased resulting in a smaller machine, the requirement for fewer machines, a smaller installation, a lighter installation and/or significantly increased efficiency of separation.

Screen life is an economic factor in the operation of solids separation equipment. It has found that screen life of fine meshes can be relative to the volume of solids to be separated by the screen. A method of reducing the volume of solids to be separated by a fine screen is to pre screen the fluid reaching the fine screen with meshes that remove coarser solids leaving the fine mesh to remove only a limited quantity of the solids contained in e.g. mud returning from an oil well in process of being drilled. The process of removing solids with progressively finer screens may be referred to as ‘Progressive Screening’. To achieve ‘Progressive Screening’ a number of conduits may be arranged in series such that each conduit is fitted with a progressively finer mesh and the two fluid streams exiting each conduit are each screened with progressively finer meshes.

As an alternative the invention may be employed after fluid containing solids, (for example returning for processing from an oil well being drilled), has initially been processed with progressively finer meshes using conventional equipment and methods. Employment of the invention in this manner allows coarser solids to be removed prior to the invention acting to concentrate the finer solids into a smaller volume of fluid for subsequent processing. This approach has the advantage that the process capacity of conventional equipment is highest when removing coarse solids and lowest when removing fine solids. Employing the invention to process pre screened fluid extends fine screen life while significantly reducing the volume of fluid to be processed by the equipment further downstream of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Further preferred features and advantages of the present invention will appear from the following detailed description given by way of example of some preferred embodiments illustrated with reference to the accompanying drawings in which:

FIGS. 1( a to c) illustrate schematically the operation of prior art vibratory screening machines;

FIGS. 2 a and 2 b illustrate schematically use of apparatus of the invention in combination with a vibratory screening machine;

FIGS. 3 a, 3 b and 3 c illustrate schematically apparatus of the invention;

FIGS. 3 d to 3 g illustrate schematically further apparatus of the invention;

FIGS. 4 a to 4 k illustrate schematically apparatus of the invention in use with vibratory screening machines;

FIG. 5 illustrates schematically apparatus of the invention in use with a centrifuge;

FIGS. 6 and 7 illustrate schematically alternative conduits;

FIGS. 8 a to 8 e illustrate schematically alternative conduits;

FIGS. 9 a and 9 b illustrate schematically prior art screening systems;

FIG. 10 illustrates schematically a screening system of the invention; and

FIG. 11 illustrate schematically an apparatus of the invention integrated with a shale shaker.

DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO SOME PREFERRED EMBODIMENTS

Prior Art

A typical (prior art) vibratory screening machine is shown schematically in FIG. 1 a and indicated by the reference numeral 1. The general method for dealing with solids/liquid separation is as follows.

The solids and liquid mixture feed (slurry) 2 is fed onto a screen 4 as a relatively thin layer or pool 6. The screen may be a wire mesh or made of other suitable screen material. The action of gravity and the vibratory motion 8 (that may be applied in a number of ways such as are well known in the art) assists undersize solid to pass through the screen together with liquid, as a screened slurry 9. The vibratory motion 8 causes oversize solids 10 to ‘walk up’ the screen and be conveyed to the oversize discharge 12.

Classification difficulties can arise where the solids contained in the fluid that are under screen size do not reach the screen face and hence pass through the screen. These undersized solids will be discharged together with the oversize solids. If the fluid fails to pass through the screen and reports to the oversize discharge 12 it will generally carry undersize solids with it, consequently reducing classification efficiency.

A key requirement is that the screen apertures remain open to allow solids to pass through the screen. A common problem experienced is screen ‘blinding’. This occurs when solids become trapped in the apertures of the screen. When ‘blinding’ occurs the number of apertures in the screen is reduced, the effective size of the apertures is reduced and the process capacity of the screen is reduced. The performance and often the operating life of a screen suffering ‘blinding’ will be different from a screen that is not ‘blinded’.

In conventional equipment multiple methods of eliminating or reducing blinding are employed. Typically these may include but are not limited to: the use of shaped apertures, wedgewire screen construction, layered wire meshes, the screen motion and frequency of screen vibration.

Other problems that can limit the efficiency of this type of screening apparatus include agglomeration of the oversize solids 10. Oversize solids can form agglomerations or a thick bed of solids on the screen 4 face that contain, trap or act as a filter to trap undersize material. Generally it is recognised that once an agglomeration or bed of dewatered or partially dewatered solids is formed, any undersize solids in the agglomeration or bed can be trapped inside the agglomeration and will thereafter report to the oversize fraction. To counteract this tendency low feed rate may be employed or liquid sprays may be used to break up agglomerations.

Historically machines of this type have been constructed as a compromise between the need to enhance fluid throughput, provide sufficient screen area to achieve the required throughput and transport solids from the screen face. Typically prior art machines have incorporated features such as illustrated schematically in FIGS. 1 b and 1 c.

The machine 1 of FIG. 1 b has a screen 4 inclined at a screen angle of typically between 0 and 15 degrees. As the screen angle is increased the depth of the pool 6 increases and the screen throughput increases as a consequence (an increased head [indicated by h] of feed). However as the angle of the screen increases the speed of transport of solids 10 up the screen face to the point of discharge generally reduces.

The section 14 of the screen 4 that is processing the feed 2 is generally referred to as the fluid pool. The length of the fluid pool will typically be between 20 and 70 percent of the screen length. The section of the screen that is drying the oversize solids 10 retained on the screen and transporting those solids to the screen discharge 12 is termed the beach 16. The length of the beach will typically be between 20 and 60 percent of the screen length. Typically the fluid content of the solids discharged (the dryness of the oversize solids) will be affected by the length of the beach 16.

FIG. 1 c shows an arrangement similar to that of FIG. 1 b except that the screen 4 has a generally horizontal section 14 where the fluid pool 6 collects, before the inclined beach 16.

In addition to the above some machines have incorporated multiple screen decks with feed mechanisms that allow the feed stream to be split between the decks, and can allow series or parallel processing of the slurry on those decks.

The New Method

The new method is illustrated schematically in FIGS. 2 a and 2 b. FIG. 2 a shows a vibratory screening machine 1 of the same general form to that shown in FIG. 1. A feed 2 of oil well drilling mud and drill cuttings is being processed. The % figures indicate a typical breakdown of the range of volume of the feed that may be processed in each stream (indicated by arrows).

Before the feed 2 is fed onto the machine 1 it is passed through conduit 18, where as indicated by arrows a first, cleaned or screened, stream C1 is separated off by passing through the screen 20 of a screening portion 22 of the conduit 18. The screen 20 has a mesh sized so that the first stream C1, in this example, is suitable for recycling directly to the drill mud supply tank (not illustrated) used for more drilling operations. i.e. the particles passing through screen 20 with the accompanying liquid are of a suitable size for reuse as drilling mud components.

The remaining feed 2 constitutes a second stream 24 that is relatively concentrated in terms of larger particles (oversize with respect to screen 20) vs. liquid content. the remaining feed is directed to the vibratory screening machine 1 where the second stream is screened on the screen 4 as described above with respect to the prior art. The oversize (with respect to screen 4) particles of solids 10 are discharged for disposal at the end of the screen 4 and the screened liquid and undersize (with respect to screen 4) solids form a cleaned stream C2 that can be added to first stream C1 for reuse.

The volume of feed 2 passed through shale shaker 1 is therefore greatly reduced allowing the shale shaker to be smaller in size and/or allowing the use of fewer shale shakers to process a given feed 2.

The % by volume of the various streams produced and processed in a typical oil well drilling operation is indicated in FIG. 2 b. As can be seen the oversize solids 10 represents only about 5% of this volume. The concentration in the second stream 24 to a mixture of about 25% liquid (plus undersize solids) and 5% oversize solids allows much more efficient throughput in the shale shaker 1.

FIGS. 3 a to 3 c illustrate an example apparatus 25 including a conduit. In this case the apparatus is in the form of a stand alone module. The module may be used as part of a system of the invention. However similar arrangements may be used as part of an integrated machine that carries out additional processing. The conduit 18 is shown in perspective view, partially cut away to allow viewing of the internal structure in FIG. 3 a and in cross section elevation in FIG. 3 b. A perspective view is shown in FIG. 3 c.

The conduit 18 forms a box like structure or basket, with a U shaped flow path 26, indicated by the arrow marked FLOW, for the feed 2 and consequent second stream 24, when viewed in elevation (FIG. 3 b).

The apparatus 25 is mounted for vibration on mounts such as springs 28 and is vibratable by any means such as well known in the art. As an alternative to a separate vibrating arrangement the apparatus may be mounted together with a screen or screens in a vibrating basket such as found in a typical shale shaker. In such an arrangement the apparatus 25 may be an integral part of flow dividing apparatus that directs slurry to selected screens in a stack for parallel or series processing such as described in WO2004/110589 (Axiom Process Limited).

A solids and liquids mixture feed 2 passes down the vertical inlet end 30 to the generally horizontally disposed screening portion 22 fitted with mesh 20 (only partially shown) for upwards filtration of the feed 2, resulting in first stream C1 containing liquid and solids of below the mesh 20 size, and second stream 24. Second stream 24, typically between 20 and 80 percent by volume of the feed 2, then passes up through two outlet ends 32 at either side of the screening portion 22 and over their associated weirs 34 (bottom edges of slots 35 in the outlet ends) from where it is directed for further processing (liquids and solids separation) typically in a shale shaker or assembly of shale shakers. Only one each of the outlet ends 32, weirs 34, slots 35 and side walls 36 are shown in FIG. 3 a due to the cut away.

Side walls 36 and the inlet end 30 contain flow C1 so that after passing through the screen 20 it is directed out of the basket between the two outlet ends 32. As it has already been processed through screen 4, C1 may be passed to the mud system for reuse or if required subjected to chemical or further mechanical processing.

High volumetric throughput is achieved by screen 20 due to the head of fluid and vibratory action acting on the screen. The head of fluid results from the differential in height H between the screen 20 and the weirs 34.

The design of outlets 32 is an important feature of the invention. The dimension of these ducts must be such that the velocity of the liquid/solids mixture of the second stream 24 during operation is sufficiently high for the solid to be carried forward over weirs 34. These can be readily determined from a consideration of the expected relative densities of the particles, the liquid employed, the flow rate into the inlet end 30 and simple tests. Advantageously the height H is made adjustable, for example by the provision of moveable plates (not shown) that can partially cover the slots 35 in the outlet ends 32.

Alternative conduit designs are possible. FIG. 3 d shows schematically in elevation an alternative apparatus 25. The conduit is arranged with the inlet end 30 above the screen 20 and having a discharge orifice 37 located below the screen 20. The rate of discharge is controlled by a size of the discharge orifice 37. The orifice may be fixed size or variable. If variable it may be manually controlled or controlled by an automated control system such that a head of fluid h is maintained within the conduit and the resulting pressure assists flow of the fluid through the screen 20. If controlled automatically or manually the head of fluid h may be varied to increase or decrease to achieve the required process flow rate of the screen to process the flow 2 arriving at the inlet.

In an alternative embodiment of the invention shown in FIG. 3 e the apparatus 25 may be configured with two layers of screen 20, 20 a. In this example the apparatus is arranged similarly to that in FIG. 3 d, making use of orifice discharges 37,37 a, but two (or more) screen stages may be obtained when making use of weir arrangements as in FIGS. 3 a,3 b, 3 c.

In FIG. 3 e the feed 2 passes through initial screen 20 creating a partially cleaned fluid stream C1 a proportion of which then passes finer screen 20 a to produce cleaned stream C2. The fluid and solids passing the first screen 20 but not the second stream 20 a form a further second stream 24 a. The cleaned stream C2 passing the two screens 20,20 a may be e.g. passed for recirculation to an oil well or be subject to further processing. Second stream 24 a passing the first screen 20 but not the second screen 20 a may be either passed for recirculation to an oil well, subject to further processing or recombined with the stream 24 not passing either screen. The aim of this arrangement may be to protect the fine screen 20 a and increase its operating life. Additionally second stream 24 a will contain particles classified in size between the two screen mesh sizes. These screens 20,20 a may be selected so that the particles in second stream 24 a are of a desirable size range for reuse. For example the two screens 20,20 a may be used to select desired particulates such as lost circulation material for recycling into an oil well drilling mud.

The apparatus 25 may be fitted with more than two layers of screens 20 producing multiple fluid streams that may be either recombined or processed in any combination as suitable to the application.

FIG. 3 f shows schematically an alternative arrangement where the apparatus 25 is fed by a pump P. A weir 34 (that may be fixed or variable height) is also employed. The combination of weir 34 and pump P allows control of the velocity of the feed through the conduit and the rate of the flow through screen 20.

FIG. 3 g shows a similar arrangement to that of FIG. 3 f except that the second stream 24 exits apparatus 25 by an orifice 37 (fixed or variable) rather than over a weir.

Further examples of conduit arrangements are shown in FIGS. 6, 7 and 8 as described hereafter.

Apparatus such as that shown in FIG. 3 can be operated as a stand alone unit or integrated in to a screening machine such as a vibratory screening machine.

Many alternative configurations are possible and schematic illustrations of these are shown in FIG. 4 with apparatus 25 shown accepting feeds 2 and dividing them into cleaned first streams C and concentrated second streams 24. The screens in apparatus 25 are not shown in these schematics, for clarity. Also not shown are details of shale shaker machines, for example flow back pans that may be provided between screens mounted in a stack to control direction of screened fluid.

Depending on the nature of the feed, it may be desirable to screen large solids out of the feed, prior to processing. A screen to remove coarse particles is normally referred to as a scalping screen. An apparatus such as the arrangement of FIG. 3 can be operated with or without a scalping screen to remove relatively coarse particles from the feed 2.

FIG. 4 a shows the arrangement as in FIG. 2 a where no scalping screen is used, the feed 2 is processed in the apparatus 25 containing the conduit. The second stream 24 is then processed through a shale shaker 1 in this example.

In FIG. 4 b a scalping screen 38 is fitted before the apparatus 25 that includes the conduit. In this example the solids 40 from the scalping screen are combined with the solids (oversize 10) from the screening apparatus 1, but they may be kept separate if required.

In FIG. 4 c the apparatus 25 containing the conduit is integral with a single deck shale shaker machine 1. For example a single basket or container that is vibrated may contain both apparatus 25 and the screen (or screens) of the vibratory screening machine 1.

In FIG. 4 d an integral arrangement as in FIG. 4 c is shown but also including a scalping screen 38 to screen large particles in advance of processing through apparatus 25.

In FIG. 4 e the arrangement is as in FIG. 4 d, including a scalping screen 38 but with a second screen 42 fitted below the first screen 4 of the screening machine 1. The scalping screen 38 is optional. The second screen 42 may be provided as an integral part of the machine 1, in this example below and in the same vibrating basket as first screen 4. Alternatively the second screen 42 may be provided in a separate vibrating basket or even in a separate machine. The second screen 42 is operating in series with the first, receiving the screened slurry 9 and screening it again to produce the second cleaned stream C2. Generally the second screen 42 has a finer mesh than the first 20. Further screens 42 may be fitted in a stack of screens if required (typically a total of three in a stack).

In FIG. 4 f the arrangement is as shown in 4 e except the two screens 4 and 42 of the screening machine 1 are operating in parallel with the second stream 24 (concentrated with oversize solids) being divided onto both screens 4 and 42, each of which produces a C2 cleaned stream. Parallel processing has the advantage of increasing throughput in the machine 1 as the screen area employed is doubled. As with FIG. 4 e the scalping screen 38 is optional. Also as with FIG. 4 e the two screens 4, 42 are provided as a stack in a single screening machine, fitted with suitable flow divider to allow parallel processing. Alternatively the screens 4,42 may be in separate vibrating baskets or even in separate machines 1.

Conveniently the arrangements of FIGS. 4 e and 4 f can be obtained with one set of equipment by providing a screening machine 1 that includes a flow directing arrangement that is switchable—either dividing second stream 24 to the two screens 20 and 42 acting in parallel (FIG. 4 f) or directing all to the first screen 20 and then directing the resulting screened slurry 9 to the second screen 42 for a series operation (FIG. 4 e). A screening machine with such a switchable flow distributor is described in WO2004/110589 (Axiom Process limited).

FIG. 4 g shows schematically a composite arrangement where two arrangements (two modules 44, 46) such as shown in FIG. 4 d are provided. The feed 2 is divided into two streams 2 a and 2 b for processing in parallel through each apparatus 25 a and 25 b. Optional scalping screens 38 a and 38 b are shown in this example but the solids flow from them is omitted for clarity. The second streams (24 a, 24 b) from each apparatus 25 are processed through the corresponding screening machines 1 a and 1 b. Thus cleaned streams C1 a,C1 b,C2 a and C2 b are produced This arrangement can conveniently be provided as a single integral apparatus with side by side or vertically stacked apparatus 25 a, 25 b and screens 4 a and 4 b mounted together in a single vibrated basket or container or in an adjacent pair of baskets. Multiple screens in stacks may be provided as in FIG. 4 e and parallel or series processing through them may be used.

The two modules may be operated with the screens 4 a and 4 b in parallel as illustrated in FIG. 4 g or in series as in FIG. 4 h (optional scalping screens not shown). In 4 h the cleaned stream C2 a from the screen 4 a of the first module 44 being processed further in the second module 46 (with a finer screen mesh 4 b used). In this arrangement the two apparatus 25 a and 25 b are fitted with a mesh 20 (not shown for clarity) that is as fine as that of screen 4 b. This ensures that all the cleaned streams (C1 a, C2 a, and C2 b) are processed through a mesh of the same size. Advantageously screen 4 a may be coarser than screen 4 b. Coarser screens generally have a longer life. At the same time as the feed to fine screen 4 b (stream C2 a) has been first passed through 4 a the life of screen 4 b will also be extended.

It will be appreciated that other arrangements are possible, for example a two module arrangement may be used with the modules 44, 46 operating in parallel with each other as in FIG. 4 g or they may be operated in series with all the feed 2 directed to the first module 44 and the resulting cleaned streams C1 a and C2 a combined and used as the feed for the second module, flowing into apparatus 25 b.

An alternative two module arrangement is illustrated in FIG. 4 i. Module 44 contains only an apparatus 25 a from which the cleaned stream C1 a is passed to a storage tank for reuse and second stream 24 a is fed to the apparatus 25 b of the second module 46 for dividing again into a cleaned stream C1 b and a second stream 24 b that is processed through screening machine 1 b that in this example is an integral part of module 46.

Alternative two module arrangements are shown in 4 j and 4 k.

In 4 j modules 44 and 46 are used to process feed 2 in series, producing one cleaned stream C1 b and both second streams 24 a and 24 b are directed to vibrating shale shaker type screen 4 provided in the second module 46.

In FIG. 4 k modules 44 and 46 are used in series and 24 a and 24 b second stream flows are then processed in series through successive screens 4, 42 of a separate shale shaker 1.

FIG. 4 l shows schematically a use of the apparatus 25 after a solids and liquid feed such as a used drilling mud from an oil well has been processed through a shale shaker stage. The feed 2 has been progressively screened through two screens (coarse and finer) 4 and 42 of a shale shaker 1 a. The feed, free of large particulates is then processed through apparatus 25. The second stream 24 produced from apparatus 25 is then screened through a (finest) mesh in shale shaker 1 b. The two cleaned streams C1 and C2 can be combined if desired. This approach reduces the load on the finest screens employed in the process, (the screen in apparatus 25 and the screen in shale shaker 1 b) by first removing the larger particles in shale shaker 1 a.

FIG. 4 m shows schematically the use of an apparatus 25 with 2 screens (e.g. as described in FIG. 3 e) producing two concentrated second streams 24 and 24 a. The details of the outlet system of 25 are not shown for clarity. The apparatus 25 produces cleaned stream C1, fluid and solids passing through both screens 20 and 20 a. The second stream 24 not passing through screen 20 is processed in shale shaker 1 a to produce cleaned stream C2. The second stream 24 a passing through screen 20 but not screen 20 a may be processed (following path A) together with stream 24 in shale shaker 1 a, contributing to cleaned stream C2.

Alternatively stream 24 a follows path B and is processed in shale shaker 1 b, producing cleaned stream C3. This allows the classified solids (sized between screens 20 and 20 a) of stream 24 a to be collected separately for reuse if desired.

The cleaned streams C1, C2, C3 may be combined for reuse.

In general any combination of apparatus 25 of the invention may be operated in series or parallel with any combination of screens operated in series or parallel either as an integrated machine or with the apparatus 25 and screens as separate machines.

Different combinations of screens (different aperture/mesh sizes) may be used with any combination of machines 25.

The apparatus 25, for example as shown in FIG. 3 may be used to concentrate the solid in a fluid stream to be passed downstream of the invention to process equipment other than screening apparatus. Decanting centrifuges and screen bowl centrifuges are commonly used to process oil well drilling mud. These machines can be expensive and be limited in their volumetric capacity. As demonstrated in FIG. 5 the invention may be employed ahead of such equipment (e.g. centrifuge 48) to reduce the fluid volume that is required to be processed by that equipment. The equipment (e.g. centrifuge 48) is required to process a fluid stream of significantly reduced volume into which solids above screen size are concentrated. Combinations of centrifuges or other solids/liquids separators may be used, in series or parallel as with vibratory screening machines. Thus apparatus 25 may be employed with trains of centrifuges operating in series or parallel.

FIG. 6 illustrates schematically an alternative conduit design to that of the apparatus 25 of FIG. 3. In FIG. 6 the conduit 18 has a screen 20 that is in a vertically disposed screen portion 22. The feed 2 flows down the conduit past the screen 20 where a first stream C1 passes out onto a plate 50 from where it can be directed, for example by side walls (not shown) as desired, for example to a holding tank (also not shown). The second concentrated stream 24 passes round the U shaped path defined by the conduit 18 and may be processed further by a screening machine.

FIG. 7 illustrates schematically a yet further alternative conduit design to that of the apparatus 25 of FIG. 3. In FIG. 7 the conduit 18 has a screen 20 that is in a downwardly angled screen portion 22. The feed 2 flows down the conduit past the screen 20 where a first stream C1 passes out from where it can be directed, for example by falling into a second conduit (not shown) as desired, for example to a holding tank (also not shown). The second concentrated stream 24 passes round the U shaped path defined by the conduit 18 and may be processed further by a screening machine.

FIG. 8 a shows in schematic elevation a conduit 18 provided with an internally located screen 20, in this example a series of circular cross section pipes 52 (see cross section along X-X, FIG. 8 b). The pipes include screens 20 as at least part of their walls. As the feed 2 passes through the conduit a first cleaned stream C1 is formed by screening through the screens of the pipes 52 and exits the conduit 18 via the branch 54. The second concentrated stream exits the conduit via the outlet end 32 of the conduit 18 for further processing as desired.

FIGS. 8 c and 8 d are cross section schematics as in FIG. 8 b but illustrating alternative pipes 52. In FIG. 8 c they are hexagonal in cross section. In FIG. 8 d rectangular. Designs such as these may be used to adjust the flow rate through the screens 20, depending on the amount of screen 20 surface area desired for a given application. Similarly FIG. 8 e shows a simpler arrangement where a screen 20 divides the available volume of the conduit screening portion in two.

FIGS. 9 a and 9 b illustrate prior art screening systems such as are used in oil well drilling operations to clean drilling mud for reuse.

The following description for FIGS. 9 and 10 follows the cleaned stream C through each stage of the system; at each stage solids removed are discarded. Pumps are indicated by P in these figures.

In FIG. 9 a the system includes low efficiency shale shakers (typically using up to 100 mesh screens) 56 (three required in this example) that process the feed 2 from a drilling operation. The screened feed is passed into a shaker holding tank 58 and then passed to a desander holding tank 60. It is then pumped to desander hydrocyclones 62 from where the cleaned stream passes to a desilter tank 64. The cleaned stream is then passed through a mud cleaner comprising a set of hydrocyclones 68 and a shale shaker 70. Next the cleaned stream is passed to centrifuge tanks 72 from where it passes through centrifuges 74 and finally to the cleaned mud storage tank (not shown).

In FIG. 9 b the low efficiency shale shakers 56 of FIG. 9 a are replaced with high efficiency shale shakers (five) 76 working with screen meshes typically at up to 200 mesh. This finer screening requires a greater number of shaker machines 9 or alternatively more screen decks within the shale shakers used) but allows the desander and mud cleaner of FIG. 9 a to be discarded. The cleaned stream is sent directly to centrifuge tanks 72 for subsequent processing by centrifuges 74. Thus the footprint and complexity of the system has been reduced by the use of high efficiency shale shakers.

FIG. 10 shows an example system of the invention. An apparatus 25 such as described before, operating at up to 400 mesh screen, works together with three high efficiency shale shakers 76 also operating with up to 400 mesh screens to produce cleaned stream C that is further processed by the centrifuges 74. The combination of the apparatus 25 and high efficiency shale shakers 76 can produce a highly screened stream C efficiently with a lower footprint, complexity and capital cost in comparison with those of FIGS. 9 a and 9 b. It will be understood from the forgoing description that many other apparatus and shale shaker arrangements may be employed in a system, for example shale shakers with integrated apparatus 25 such as shown in FIG. 4 c may be employed.

FIG. 11 a shows in schematic perspective an alternative arrangement to that of FIGS. 3 a to 3 c. It may be mounted for vibration in a similar fashion to that described for the FIGS. 3 a to 3 c apparatus. In FIG. 11 a apparatus 25 includes a conduit 18 with a vertical inlet end 30 passing the feed 2 down to a generally horizontally disposed, box like, screening portion 22, fitted with mesh 20 for an upwards filtration that produces cleaned first stream C1. The first stream C1 is directed out of the apparatus 25 with the assistance of walls 36. Typically the stream C1 will be fed by gravity and/or by pump to a storage tank for reuse, optionally after further processing.

The second stream 24, concentrated in solids content (solids greater than the size of mesh 20), passes out of outlet end 32, over weir 34. In this example the second stream 24 is then processed further by a vibratory screen or screens indicated by schematic inclined screen 4 in the drawing. Oversize (for screen 4) solids 10 are “walked up” screen 4 by the vibratory action and leave by discharge 12. Cleaned stream C2, passing through screen 4 may be further processed or combined with stream C1 as appropriate.

The arrangement of FIG. 11 a, having inlet end 30 at right angles to outlet 32, with the screening portion 22 in between, provides a turbulent flow. The feed 2 flowing into the box like screening portion 22 will swirl as filtration through screen 20 occurs and as the outlet 32 takes the second stream 24 out in a different direction to that of the feed flow.

The arrangement of FIG. 11 a may be used in a stand alone module, or as a modular part of a system as discussed above with respect to the arrangement of FIGS. 3 a to 3 c.

Alternatively and as shown in the schematic elevation of FIG. 11 b the apparatus 25 may conveniently be provided as an integral part of a vibratory screening machine, in this example a shale shaker 1.

In FIG. 11 b apparatus 25, for example of the form shown in FIG. 11 a, is fitted into a basket (indicated schematically by broken line 78) of a shale shaker 1. The basket is subject to vibratory motion in the usual way. The basket includes two scalping screens 38 and 38 a and two screens 4 and 4 a for processing solids and liquid mixtures. Flow back pans 80, 80 a are provided between screens in the stack of screens in the basket, to direct filtrate passing through the screens for onwards processing in the usual way.

A solids and liquid feed 2 such as a used drilling mud including drill cuttings is passed through scalping screen 38 before entering the inlet end (not shown in this drawing, see 30 in FIG. 11 a) of apparatus 25. The scalping screen 38 removes large particulates such as chunks of drill cuttings that are walked along screen 38 and then 38 a to discharge 12 a by the vibratory motion.

The feed 2 is then processed by the apparatus 25, producing first stream C1 for reuse as drilling mud (with or without further processing as appropriate). The concentrated stream 24, passing over the weir 34 is then fed into a flow distributor 82 that may be a switchable flow distributor as described in WO2004/110589 (Axiom Process limited). The flow distributor 82 acts to divide the stream 24 into two parts 24 a and 24 b for parallel processing on screens 4 and 4 a (of the same mesh size) respectively.

Solids 10 filtered off by the screens 4 and 4 a are walked up the screens and discharged at 12 b and 12 c in the usual fashion. The cleaned stream C2 produced from screen 4 is directed by flowback pan 80 a and flow distributor 82 out of the bottom of basket 78. The cleaned stream C3 passes out of the bottom (sump) of the basket 78. As desired or required the streams C2 and C3 may be combined, in the sump of the basket 78 or elsewhere. They may also be combined with stream C1 to produce a single stream of reuse/recycle.

If a switchable flow distributor 82 is employed then the equipment of FIG. 11 b may be readily reconfigured to provide series processing; processing all of stream 24 through screen 4 and the resulting filtrate through screen 4 a. This allows progressive screening through screens of decreasing mesh size (using a screen 4 a of finer mesh than that of screen 4). If series processing is used the solids from discharge 12 b may be collected separately from those of the other discharges. These solids have been classified between the mesh sizes of screens 4 and 4 a. With appropriate choice of mesh sizes the classified solids can comprise e.g. the weighting agent that is a desired component of drilling mud or a “lost circulation material” that is often added to drilling mud to block cracks or other defects in a well bore. 

1. An apparatus for use in screening a liquid and solids mixture feed, the apparatus comprising: a conduit, including a screening portion and formed and arranged to divide a liquid and solids mixture feed flowing through the conduit into a first, cleaned stream comprising liquid and solid particles of below a selected size limit, and a second, concentrated, stream comprising liquid, and particles above the selected size limit.
 2. An apparatus according to claim 1 wherein at least the screening portion of the conduit is subject to vibration provided by vibration means.
 3. An apparatus according to claim 2 wherein at least the screening portion of the conduit is: mounted on resilient mountings; or is located in a basket mounted on resilient mountings; and the screening portion of the conduit or the basket containing it is subject to vibration by the vibration means.
 4. An apparatus according to claim 1 wherein the conduit is a pipe or channel having a screen mesh or other filter material that replaces part of its wall.
 5. An apparatus according to claim 1 wherein the conduit incorporates a secondary, internal conduit, for example a pipe, that has a portion of wall replaced by a screen mesh or other screen or filter material.
 6. An apparatus according to claim 1 wherein the conduit comprises at least two screens, provided in one or more screening portions of the conduit, wherein the at least two screens are formed and arranged to operate in a series fashion whereby the first, cleaned stream is passed successively through both screens.
 7. An apparatus according to claim 1 wherein the conduit is formed and arranged so that the screening of the feed effected by the screening portion of the conduit is carried out in an upwardly flowing direction through the screening portion.
 8. An apparatus according to claim 1 wherein the conduit is formed and arranged so that the screening of the feed effected by the screening portion of the conduit is carried out in a downwardly or a horizontally flowing direction through the screen.
 9. An apparatus according to claim 1 formed and arranged so that the screening is carried out at a slight positive pressure provided by one or more of the following: an inlet for the conduit is at a height greater than the height of the screening portion of the conduit; an outlet for the conduit, in the form of a weir or an orifice, is at a greater height than the screening portion of the conduit; a pump supplies the liquid and solids mixture feed to the conduit; and an outlet orifice from the screening portion of the conduit is restricted with respect to the size of the inlet flow.
 10. An apparatus according to claim 9 wherein at least one of: inlet height; outlet height; pumping rate; and outlet orifice size; is manually or automatically variable to adjust the flow rate and the pressure applied for screening.
 11. An apparatus according to claim 9 wherein the screening portion of conduit has a portion of screen mesh or other filter material on an upwards facing portion of wall and the feed is supplied at a slight positive pressure so as to effect upwards filtration through the screen mesh.
 12. An apparatus according to claim 9 wherein the screening portion of conduit has a portion of screen mesh or other filter material on a vertical or downwards facing portion of wall and the feed is supplied at a slight positive pressure so as to effect horizontal or downwards filtration through the screen mesh.
 13. An apparatus according to claim 8 wherein the conduit: a) is mounted in a vibrating basket or is itself mounted on resilient members and is directly vibrated; b) has a downwards directed, for example vertical, inlet end followed by a generally horizontally disposed screening portion that has a screen mesh replacing a portion of conduit wall; and c) the conduit continues by having an upwardly directed, for example vertical, outlet end at a lower height than the inlet end.
 14. An apparatus according to claim 1 further comprising a scalping screen, formed and arranged to remove large particles from the liquid and solids mixture feed before it flows through the conduit.
 15. An apparatus according to claim 14 wherein the scalping is subject to vibration by vibration means.
 16. A method of screening a liquid and solids mixture feed, the method comprising: providing a conduit, including a screening portion and formed and arranged to divide the feed flowing through the conduit into a first, cleaned stream comprising liquid and solid particles, of below a selected size, and a second, concentrated, stream comprising liquid and particles above the selected size; and passing a liquid and solids mixture feed through the conduit.
 17. A method according to claim 14 wherein the method further comprises: directing the second stream to an apparatus for further processing.
 18. The method according to claim 17 wherein the second stream is processed by a method comprising passing the second stream through at least one of a vibratory screening machine, a centrifuge and a hydrocyclone.
 19. A method according to claim 16 wherein the method further comprises: processing a liquid and solids mixture feed through at least one of: a scalping screen, a vibratory screening machine, a centrifuge and a hydrocyclone: before passing a resulting liquid and solids mixture feed through the conduit.
 20. (canceled)
 21. A method according to claim 17 wherein the at least one apparatus employed to process the second stream is a shale shaker.
 22. A system for screening a liquid and solids mixture feed, the system comprising: an apparatus including a conduit, the conduit including a screening portion formed and arranged to divide a liquid and solids mixture feed flowing through the conduit into a first, cleaned stream comprising liquid and solid particles of below a selected size limit, and a second, concentrated, stream comprising liquid, and particles above the selected size limit; and screening or liquid and solids separating apparatus for processing the second stream.
 23. A system according to claim 22 wherein the apparatus including a conduit is as wherein at least the screening portion of the conduit is subject to vibration provided by vibration means.
 24. A system according to claim 22 wherein the screening apparatus for processing the second stream is selected from the group consisting of hydrocyclones, centrifuges, decanting centrifuges, vibratory screening machines such as shale shakers, and combinations thereof.
 25. A vibratory screening machine for separating solids from liquid, in a liquid and solids mixture feed, the machine including as an integral part: an apparatus comprising: a conduit, including a screening portion and formed and arranged to divide a liquid and solids mixture feed flowing through the conduit into a first, cleaned stream comprising liquid and solid particles of below a selected size limit, and a second, concentrated, stream comprising liquid, and particles above the selected size limit.
 26. A vibratory screening machine according to claim 25 wherein the apparatus is mounted in the vibrating basket of a shale shaker.
 27. A vibratory screening machine according to claim 26 formed and arranged so that the second concentrated stream comprising liquid and particles above the selected size limit is fed to one or more screens of the shale shaker for further processing.
 28. A vibratory screening machine according to claim 26 formed and arranged so that the liquid and solids mixture feed is processed through at least one scalping screen of the shale shaker, before being fed to the apparatus comprising: the conduit.
 29. A vibratory screening machine according to claim 26 further comprising a switchable flow distributor formed and arranged to: receive the second concentrated stream from the apparatus comprising the conduit; and to divide said second concentrated stream to feed, in parallel, a stack of at least two vibrating screens in the basket; or to feed said second concentrated stream successively through a stack of at least two vibrating screens in the basket.
 30. A system for screening a liquid and solids mixture feed, the system comprising: screening or liquid and solids separating apparatus for processing the feed to produce at least one processed liquid and solids mixture stream; followed by an apparatus including a conduit, the conduit being formed and arranged to receive the at least one processed liquid and solids mixture and including a screening portion formed and arranged to divide the processed liquid and solids mixture flowing through the conduit into a first, cleaned stream comprising liquid and solid particles of below a selected size limit, and a second, concentrated, stream comprising liquid, and particles above the selected size limit.
 31. A system according to claim 30 further comprising screening or liquid and solids separating apparatus for processing the second stream.
 32. A system according to claim 30 wherein at least the screening portion of the conduit is subject to vibration provided by vibration means. 